Published on: September 16, 2025
Elevating Safety and Efficiency at a Dassault Falcon Jet MRO
Hazard: Catastrophic fall risks from elevated work on aircraft and inefficient use of temporary equipment.
Solution: Custom-engineered overhead rigid rail and bridge systems (FlexRail and FlexBridge) provide continuous, adaptable fall protection.
Benefits: Eliminated fall hazards, streamlined operations, and created a foundation for future growth.
The Hazard
In the aviation MRO (Maintenance, Repair, and Overhaul) industry, workers must perform daily tasks on elevated and often slick surfaces of aircraft, including wings, fuselages, and tails. At a new Dassault Falcon Jet facility in Melbourne, Florida, this elevated work posed a medium fall risk with a high potential for severe injury or fatality due to the hard hangar floors and significant working heights. Relying on temporary ladders or stands was not only dangerous but also inefficient, hindering the high-volume workflow required for the new facility.
The Solution
Flexible Lifeline Systems (FLS) was brought in to engineer and install tailored, comprehensive fall protection solutions throughout the new MRO and paint hangars. All fabricated steel was hot-dipped galvanized for maximum corrosion protection and designed to attach directly to the building’s overhead structure.
- MRO Hangar: Ten rows of FlexRail systems were installed to provide continuous fall arrest protection for maintenance along the length of the aircraft. Each system was divided into three distinct work zones, allowing multiple technicians to work safely and simultaneously without interference.
- Side Draft Paint Hangar: A combination of a fixed FlexRail system and three adjustable FlexBridge systems was implemented for comprehensive and flexible fall protection during sanding, stripping, and painting. The systems were designed to match the sweep of an aircraft wing, providing optimal overhead positioning.
- Down Draft Paint Hangar: Sixteen single-point anchors were supplied as a strategic foundation for future expansion, allowing the facility to grow its capabilities without major structural changes.
This integrated approach transformed a high-risk environment into a safe, OSHA-compliant workspace, optimizing operations while protecting the facility’s most valuable assets: its people and the aircraft.
A Single-Source Solution for a Soaring Partnership
This project with Dassault Falcon Jet is a prime example of FLS’s ability to deliver turn-key solutions that solve complex challenges at height. From initial design to final installation, we provided expert project management that ensured a seamless, on-time delivery. The result is a fully compliant, performance-ready system that not only ensures maximum worker safety but also boosts operational efficiency and is built for future growth.
Ready to enhance safety and efficiency at your facility? Contact Flexible Lifeline Systems for a comprehensive safety audit and let our team of experts help you find the perfect solution for your fall protection and material handling needs.
